table of contents...autolevel™ button, the autoair™ system process is activated. jack system...
TRANSCRIPT
Technical Service Support
Table of Contents
General
1. Equalizer Systems Warranty Policy
2. Overview of the AutoLevel™ / AutoAir™ Control Panel
3. Setting the Null
AutoLevel™Jack System
1. General System operation
2. Troubleshooting Guide
3. Component Drawings
4. Manual Override Procedure
AutoAir™System
1. General System operation
2. Troubleshooting Guide
3. Component Drawings
For additional support contact us at [email protected]
Equalizer Systems P.O. Box 668, 55169 CR 3 North
Elkhart, IN 46515 Phone: (574) 264-3437 Fax: (574) 266-6083
EQUALIZER
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WARRANTY The Equalizer System shall have the following warranty coverage:
100% parts coverage for all defective parts for a period of three (3) years and 100% labor coverage for replacement of any defective parts, including shipping, for a period of one (1) year. This warranty period shall begin on the date when the Equalizer System enters into service. If the part is found to be defective, Equalizer Systems shall pay parts and shipping expense for the defective part for a period of one year. Equalizer Systems reserves the right to authorize repair, parts, replacement, shipping costs, and/or any expense having to do with warranty service, prior to any work or shipping expense is incurred. Equalizer Systems also reserves the right to authorize the location and technician to perform the service.
In the event that service must be performed, Equalizer Systems will provide labor coverage only for the allotted time issued on the “Equalizer Systems Parts Replacement Schedule” at a reasonable shop rate. Equalizer Systems will determine reasonable shop rates.
Equalizer Systems will not be responsible for improper installations, damage due to improper installation, or service, performed by parties other than Equalizer Systems. Equalizer Systems will not be responsible for any damage due to abuse, neglect, misuse, negligence, misapplication, error of operation, accidental or purposeful damage. This warranty extends to the Equalizer System only, and does not extend to the vehicle to which the Equalizer System is attached or any other apparatus or property, loss of time, manufacturing costs, labor material, loss of profits, consequential damages direct or indirect or incidental damages, whether due to rights arising under this warranty or otherwise, and whether a claim for damages is based on contract, tort, or warranty.
Written permission for any warranty claim return must be first obtained from authorized Equalizer Systems personnel. All warranty parts must be accompanied by a complete written explanation of claimed defects and the circumstances of failure.
Products manufactured or sold by Equalizer Systems are not warranted expressly or by implication for merchantability or fitness for a particular use, notwithstanding any disclosure to Equalizer Systems of the use to which the product is to be put. This express warranty is the sole warranty of Equalizer Systems. Equalizer Systems does not authorize the sale of its products under any other warranty or guarantee, expressed or implied. This warranty voids all previous issues. Effective date: November 1, 2002. Any questions
concerning this product warranty should be directed to: Equalizer Systems
P.O. Box 668, 55169 CR 3 North Elkhart, IN 46515
Phone: (574) 264-3437 Fax: (574) 266-6083
EQUALIZER
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1
AutoLevel™ Control Panel
AutoAir™ System Power Button
This button powers up the AutoAir™ system (if equipped). After depressing this button, you will be able to manually raise and lower the individual chassis airbags. This is helpful when manually leveling the coach prior to re-setting the Null. By depressing this button followed by depressing the AutoLevel™ button, the AutoAir™ system process is activated.
Jack System Power Button
This button powers up the hydraulic jack AutoLevel™ system. After depressing this button, you will be able to manually raise and lower the individual jacklegs. This is helpful when manually leveling the coach prior to re-setting the Null. By depressing this button followed by depressing the AutoLevel™ button, the AutoLevel™ jack system process is activated.
AutoLevel™ Button This button activates the AutoLevel™ process. It is used for either Air or Hydraulic jacks, depending on which system has been activated by its respective power button.
Jack System Power Button
AutoLevel™ Button
Travel Mode Button
AutoAir System Power Button Up/Down
Buttons
Level Sensor Warning Light
“Leg Stowed” Indicators
2
Travel Mode Button
In the AutoAir mode, this button disables the airbag leveling system and returns control of the airbags back to the chassis ride-height valves. In the AutoLevel™ hydraulic mode, this button retracts all of the jacks to their up/stowed position. Up/Down Buttons
In the AutoAir™ mode, these buttons are used to inflate or deflate each individual airbag to manually level the coach body. In the AutoLevel™ hydraulic mode, these buttons are used to extend or retract each individual hydraulic jackleg to level the coach. Level Sensor Warning Light
This red LED will light if there is any disruption of the signal between the level sensor and the control panel. “Leg Stowed” Indicators These red LEDs will be off when the jacklegs are completely retracted into their stowed position. If any of these LEDs is on, that particular jackleg is out of its stowed position and is partly, or completely, extended. Audio / Visual signals The control panel has been designed to generate a series of both audio signals and visual signals to indicate a given function of the panel. These signals can be very useful in troubleshooting a problem with the system in general and with the panel specifically. For a complete list of these signals, click here.
Null
The Null setting tells the solid-state level sensor where level is. The procedure is as follows:
1. Using the individual Up/Down buttons on the Control Panel and some sort of bubble level, manually adjust each airbag until the coach is level, both front-to-back and side-to-side.
2. Turn off power to the control panel, if on. 3. Depress and hold the “AutoLevel” button on the control panel, then
depress the “Air” button. The panel will begin to beep repeatedly. 4. After the panel beeps 6 or 7 times, release the “AutoLevel” button. The
Null is now set.
Setting the Null The Null setting tells the solid-state level sensor where level is. This
procedure has been initially done at the factory, but will need to be reset if either
a new control panel or a new level sensor has been installed.
The procedure is as follows:
1. Turn on power at the control panel.
2. Using the individual Up/Down buttons on the Control Panel and some sort
of bubble level, manually adjust each jack leg until the coach is level, both
front-to-back and side-to-side.
3. Turn off power to the control panel.
4. Depress and hold the “AutoLevel” button on the control panel, then
depress and release the “Power” button. The panel will begin to beep
repeatedly.
5. After the panel beeps 6 or 7 times, release the “AutoLevel” button. The
Null is now set.
Note – If the coach is equipped with the optional AutoAir™ System, either system
– Air or Hyd – can be used to level the coach for this procedure.
AutoLevel™
System Overview
The AutoLevel™ leveling system consists of a hydraulic system containing
four hydraulic jack legs connected to a hydraulic pump and manifold assembly by a
series of hydraulic hoses. This hydraulic system is controlled by an electrical
system containing an electric harness, a level sensor and a microprocessor control
panel that is the brains of the entire AutoLevel™ system.
Basic Operation
The initial level condition of the coach is done by manually lowering - then
adjusting - the four jack legs using the Up/Down buttons located on the right side of
the control panel. For reference, a set of bubble levels is used: one for side-to-side
level and another one for fore-aft level. Once the proper level condition is
established, the system Null is set. This tells the system that, anytime the
Autolevel™ command is initiated, this is the level condition the system needs to
bring the coach to. The system will do this within an accuracy of +/- 0.5 degree of
the Null setting.
When the Autolevel™ button is pressed, the system first dumps the chassis
air bags, then extends the jack legs one at a time, beginning with the front left jack
and moving clockwise to the right front, right rear and left rear jacks. The system
will extend each jack just until the jack makes contact with the ground. This is
called planting the jacks. (The chassis air bags are dumped to lower the coach
entry step as close to the ground as possible.)
Once all jacks are planted, the control panel’s patented software will “read”
the tilt being sent to it by the level sensor. It will then compare this to the Null
setting previously determined during the setting process. The software will then
calculate which corner of the coach needs to be raised (or lowered) to bring the
coach into level condition, and send the appropriate signals to the Hydraulic pump
EQUALIZER
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to adjust the jacks. The entire Autolevel™ process takes only 30 to 45 seconds to
complete.
When the coach needs to be moved, the “All Retract/Travel Mode” button is
pressed and the jacks will all retract together. The system will also return control
of the chassis air bags back to the ride-height valves, which will re-inflate the bags.
This entire process takes between one and three minutes, depending on the
condition of the batteries and the amount of chassis air available.
Bad electrical connection Trace and repairPanel on but jacks won't operate Defective Control Panel Replace
Bad electrical connectionAir in Hydraulic System Defective cartridge valve(s) on pump
Replace
ReplaceReplaceTrace and repairPurge the System Replace cartridge valve(s)
Defective Control PanelLow battery voltage
Replace
ReplaceDefective Leg Switch
Defective Pump motor or solenoidBlown fuse in fuse box
Charge Vehicle batteries
Replace
Level Sensor harness defectiveLevel Sensor defectiveDefective Control Panel
Excess vehicle movement during levelingSystem Null not setDefective Leg Switch Replace
Trace and repairReplace
Trace and repair
Charge Vehicle batteriesReset Control Panel and try againSet Null
Replace fuseTrace and repair
Replace
Charge Vehicle batteries
Charge Vehicle batteriesRepair
Replace
Charge Vehicle batteriesTrace and repair
Low battery voltage
Incorrect wiring on pump valves
Bad electrical connectionIncorrect Hose connection at pump or jack
Set Null
ReplaceDefective Control Panel
Ignition switch in wrong positionDefective Leg Switch
Defective Control PanelCheck and change if necessaryReplace
Trace and repairCheck and re-wire
Legs bleed down from leveled position
Blown fuse on back of Panel or in fuse boxBroken power or ground wire
Defective Control PanelLow battery voltageDefective Diode in Panel harness (if equiped)
Defective Pump motor or solenoid
System Null not set
Leg LED's on Panel stay on
Hydraulic pump inoperative
Auto-Level stops in mid-cycle
Jacks will extend but not retract
Jacks will retract but not extend
OEM Troubleshooting Guide-Hyd AutoLevelSymptom Possible Cause Corrective Action
Low battery voltage
Low battery voltageControl Panel will not turn on Defective Control Panel harness
AutoLevel™ System Drawings
Hydraulic
• Pump assembly – Components
• Pump assembly – Electrical
• Pump assembly – Hydraulic
• Jack Leg assembly – 16”
• Jack Leg assembly – 18”
• Level Sensor assembly
• Hydraulic Control Panel
AutoAir
• Air System Schematic
• Air Valve
• Compressor
• Air Tank Assembly
• Wiring Harness
• Air Control Panel
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Operation of Hydraulic Level System Manual Override
If electrical power is ever lost to the Equalizer jack leveling system, your system has been equipped with a manual override option. The following procedure will guide you step by step on how to initialize the manual override to either retract or extend the leveling jacks.
To RETRACT one or more Jacks
1. Locate the Jack System Pump The pump on your coach is located behind the access panel at the very right rear of the coach. 2. Initializing the Leg Valves Locate the Leg Valve(s) for the legs you want to operate (Items 1-4 on drawing). Using a SMALL flat blade screwdriver, turn the center screw all the way in (clockwise). 3. Initialize Manual Override Valve Locate Valve #5 located on the back of the pump. Pull the center red knob out and rotate ½ turn in either direction. 4. Initialize the Directional Valve For RETRACT only, locate Directional Valve #6 located on the front of the pump. Pull the center red knob out and rotate ½ turn in either direction. 5. Operate the Hand Pump Locate Hand Pump handle. Insert handle into the Hand Pump collar located on the front of the pump. Begin pumping the handle. Continue operating Hand Pump until jack(s) begin to retract. Note: It may require 50 to 100 strokes before any movement is noticed in the jack(s). Continue operating Hand Pump until jack(s) are retracted. 6. Return System to Normal Mode Once the jacks are retracted, you must return the Valves back to their normal modes. CAUTION: Failure to do this may result in one or more jacks drifting down from their retract (stowed) position. For Valves 1-4, rotate the center screws fully in the counter-clockwise direction. For Valves 5 and 6, simply rotate the red knob until it snaps back into its normal position. To EXTEND jack(s), follow the above procedure EXCEPT do not initialize the Directional Valve as described in Item #4 above.
1
AutoAir System Overview
Description
Under certain circumstances, it is necessary or desirable to level the
coach body but, because of local restrictions, the normal hydraulic AutoLevel™
jacks cannot be used. Equalizer Systems’ AutoAir leveling system functions by
leveling the body of the coach using the chassis airbags. A solid state level
sensor reads the level condition of the coach body and, by either inflating or
deflating the appropriate chassis airbag(s), brings the body into a level condition.
The system will periodically re-check the level condition and, if necessary, make
minor adjustments to re-level the body.
Operation
Upon parking the coach, setting the park brake, shutting off the engine
and extending the slide-outs, momentarily depress the “Air” button on the
AutoLevel™ control panel. This powers up the system. Momentarily depress the
“AutoLevel” button to activate the system.
The coach airbags will deflate for about one second - this helps to insure
that the coach step is not too far above the ground. After a slight pause to allow
the level sensor to “see” where it is, the AutoLevel™ process begins. (NOTE – it
is important to limit the amount of movement in the coach during the leveling
process. Excess movement will cause the system to shut down.) This process
takes about one minute to complete.
About every two hours, the system controller will re-check the level
condition and, if necessary, make minor adjustments to re-level the body.
When ready to travel, the system is deactivated in one of two ways. The
first is to momentarily depress the “All Retract Travel Mode” button on the control
panel. The other way is to momentarily depress the “Air” button on the control
panel, thereby shutting off the system.
2
Detailed function
The system consists of several components.
• A special Control Panel, which contains a microprocessor, controls the
functions of the system.
• A series of four Air Valves that are located under the coach near the air
bag that each valve controls. Each valve is installed between an air bag
and either the chassis Ride-Height valve or the chassis ping tank(s).
During the AutoAir leveling process, these valves block the path between
the bags and the Ride-Height system, giving them control of the bags.
• An auxiliary Air Tank, which supplies air to the AutoAir system if there is
no air in the chassis air tank.
• An auxiliary Air Compressor, which re-charges the auxiliary Air Tank as
needed. The compressor is controlled by means of an air pressure
switch located on the Air Tank.
• An electrical Harness, which ties the Control Panel and the Air Valves
together. This harness consists of two sections. One section runs from
the Control Panel to the chassis bulkhead, and another section that runs
from the bulkhead to the Air Valves.
• A series of air lines and fittings, which plumb the Air Valves together with
the Air Tank.
Set
Reset Control Panel (All Retract) and try again
Replace
Level Sensor harness defective
or more airbags
Auto-Level stops in mid-cycle
Defective Control Panel harness
Pressure switch on Aux. Air tank
Defective Control Panel
One or more airbags will not
Defective chassis componentDefective air Valve(s)re-inflate to Ride Height
Aux. Compressor Relay defective
Defective Control PanelDefective air Valve(s)
Troubleshooting Guide-Air AutoLevelSymptom Possible Cause Corrective Action
Panel on, but airbags won't System Null not setBad electrical connectionPark Brake not set (optional)
Panel will not control one
level condition
operate from panel
Home
Low battery voltage
Blown fuse on back of Panel or in fuse box
Defective Control PanelLow battery voltage
Defective Control Panel
Excess vehicle movement during levelingLow battery voltage
Aux. Air supply not functioning
Charge Vehicle batteries
Replace fuse
Replace
Charge Vehicle batteries
Charge Vehicle batteries
Replace
Trace and repairNull
Set Park Brake
Replace
Replace
Trace and repairReplaceReplace defective valve(s)
Set Null
No air in chassis air system Start engine and allow air system to chargeReplace defective valve(s)Consult Chassis Service Center
Back Drawings
System fails to maintain long-term Excessive air leak Trace and repair
Defective Control Panel harness ground Trace and repair
Trace and repairReplace
Blown fuse to Aux. Compressor
System Null not set
Level Sensor defective
Vehicle Ignition on Turn off ignition
No air in chassis air system Start engine and allow air system to charge
Control Panel will not turn on Broken power or ground wire Trace and repair
12
Visual Status Outputs #s
Status LED
Description LED Color
1 Power Sw Backlight Location LED when voltage is above 10.0V +/- 0.5V Backlight Location LED when voltage is below 10.0V +/- 0.5V
Green On OFF
Warning LED when Voltage is above 10.0v +/- 0.5V Warning LED when Voltage is below 10.0v +/- 0.5V
Red Off On
2 AutoLevel Sw ALV is activated and in progress Green Flash
Error condition - Any leg that fails to unstow initiates an error condition. Any switch press or power off will clear the error condition.
Red On
3 All Retract Sw All Retract is activated and in progress Green Flash
Error condition – any leg, which fails to stow. Any switch press or power off will clear the error condition.
Red Flash
4 LF Leg Stow Status LED
LF Leg is stowed LF Leg is extended
Red Off On
Error condition – anytime leg fails to unstow during AutoLevel or fails to stow during All Retract
Red Flash
5 RF Leg Stow Status LED
RF Leg is stowed RF Leg is extended
Red Off Of
Error condition – anytime leg fails to unstow during AutoLevel or fails to stow during All Retract
Red Flash
6 LR Leg Stow Status LED
LR Leg is stowed LR Leg is extended
Red Off On
Error condition – anytime leg fails to unstow during AutoLevel or fails to stow during All Retract
Red Flash
7 RR Leg Stow Status LED
RR Leg is stowed RR Leg is extended
Red Off On
Error condition – anytime leg fails to unstow during AutoLevel and anytime fails to stow during All Retract
Red Flash
8 All @ Power-Up
Backlight - All Location LEDs, except Power switch not in use
Green On
Visual Test – All Warning/Error LEDs located under AutoLevel switch and All Retract/Travel Mode switch, all Stow LEDs Plus Sensor LED. Power switch red & green LEDs, which is not selected, do not turn On
Red 1.5-sec
9 Sensor Sensor is On and communicating with ALV No sensor data is available Sensor data in intermittent due to harness failure Noise on sensor line
Red Off On
Flash On
10 Heartbeat Processor is active Red Flash
BACK
13
Audio Status Outputs
#s Audio Status Description 1 Denied w/Disable
On Continuous tone sounded while switch is pressed.
1a Denied w/No Disable
Uh-Uh tone sounded each time a switch is pressed
2 Failed Dual low tone (“Uh-Uh”) 3 Passed Hi tone, Low tone. (“Bedoop”) 4 Warning ½ sec. Low tones plus ¼ sec. High tones – 10-second timeout 5 Auto Operating ½ sec. Hi tones. 6 Auto Operating
failed. ¼ sec. Hi tone pulse. Indicates a continuously present error condition, which is probably indicated by one or more leg status LEDs. – continuous until any switch is pressed to clear the error condition
7 System Reset Short series of ¼ sec Hi tones – (power reset)
Timer Table #s Function Timer Description 1 All Retract -
Max 90-seconds All legs will retract automatically for a maximum of 90-seconds
2 Pump Extra On Time
3-seconds Pump outputs for Up and Down will remain On for and extra 3-seconds extra time after all legs have been stowed
3 Unstow 2-seconds In clockwise direction, each leg is unstowed for 2-seconds, then each leg is checked for stow position at 2-sec after each leg plant sequence is initiated sequentially
4 Leg Plant Max
40-seconds per leg
Each legs is extended individually for leg plant a maximum of 40-seconds – calculated individually for a combined max total of 160-sec
5 Auto-Level Max
90-seconds Auto-Level sequence, starts after Leg Plant is completed and will only try to achieve level for a maximum of 90-seconds
6 Hydraulic Sleep Mode
10-minutes Module will enter sleep at 10-minutes if the power is On and there is no keypad activity
7 Airbag Cloaking
Mode
10-minutes Module will enter sleep at 10-minutes if the power is On and there is no keypad activity
8 Airbag Cloaking
Mode
2-hours 5-minutes
Module will wake-up every 2-hours to check level, if level it will go back to sleep, if not level it will wake-up and initiate an auto-level sequence
9 Blocking 2-seconds Anytime power to hydraulic or air is turned On or Disable is not present Off, there will be a 2-second blocking signal
10 Return to Normal
1-second Anytime power to hydraulic or air is turned Off or Disable is present, there will be a 1-second Return to Normal signal
11 Hydraulic Deflate
5-seconds Anytime Auto-Level is initiated there will be 5-second All Deflate signal
12 Airbag Deflate 1-second Anytime Auto-Level is initiated there will be 1-second All Deflate signal
BACK
1
Hydraulic System Purge Process
After the installation of the hydraulic jack system, the system must be purged of air, which is replaced with hydraulic fluid. Occasionally, this process is not done adequately and some air will remain in the system. This causes the jacks not to run as efficiently as they should, and may result in the jack legs sagging out of their stowed (retracted) position. This procedure will solve the problem.
• Make sure the pump reservoir is filled with hydraulic fluid. There is a fill line on the reservoir.
• Using either the manual buttons or the All Retract button on the Control Panel, fully retract all of the jacks.
• Re-check the fluid level – add as necessary. • Using the manual buttons on the Control Panel, fully extend all
jacks to their maximum extension. This will require alternating between the front two jacks and the rear two jacks – the cross-frame twist limiter in the Control Panel will not allow you to fully extend one jack at a time. Keep the jacks extended for at least 15 minutes.
• Again, fully retract the jacks. Re-check the fluid level – add as necessary.
The process is complete.
EQUALIZER
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